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Shoji NOGUCHI
Article type: Article
Session ID: S1105-2-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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There was strong wear around the both ends of a pin up to now about wear of a pin of Laura Chen/Busch, and I made it clear that a pin central part doesn't touch Busch. I can think it's effective to expand the contact range into the whole pin and make them reduce the contact pressure to make them reduce wear of a pin/Busch. So it was confirmed by this research that contact territory feels the pin shape is wide theoretically by applying the crowning shape which could inflate a central part, not straight. I made it clear to be able to reduce more wear by an experiment.
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Yoshinori SAWAE, Hiroyuki NODA, Hiroyoshi TANAKA, Yoshie KURONO, Kazuh ...
Article type: Article
Session ID: S1105-2-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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It is important to understand the tribological characteristics of polymeric sealing materials, such as PTFE, sliding against metal counter face in the hydrogen environment to establish a design guideline for hydrogen energy systems. The aim of this study is investigating effects of hydrogen on the formation of PTFE transfer films and subsequent friction and wear behaviors. Our experimental results indicated two different effects of hydrogen. One is a promotion of the transfer film formation due to the reduction of surface oxide layer of the metal counterface, and the other is an interruption of the adsorption of PTFE molecules on the metal surface.
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Shinya Sasaki, Hiroki Mano
Article type: Article
Session ID: S1105-2-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Revision of JSME standard methods for wear test 'MSME S 013" which had been enacted in 1999, has been examined from 2006, and the revised version was enacted in April, 2010. The main revised points are introduced with some important issues which were discussed at the revision working committee.
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Ryutaro KAMACHI, Tatsuya OHMACHI, Hidenori KOMATSUBARA
Article type: Article
Session ID: G1300-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Manufacturing Center was started in Yamagata University since 2010. The system that supported the existing Machine Factory was restructured, the support system for the Manufacturing Center was developed in this research. The support system consists of the reservation system and the submission system to apply when user handles machine. The system is providing service by HTML on the www server. In this research, the system was programmed with PHP, and the database was built by MySQL. The utilization, the administration, and the management of the Manufacturing Center became more convenient by this system.
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Yukio Maeda, Kenichi Iwatsuka, Takanori YAZAWA, Yohei FUKUDA, Shinya S ...
Article type: Article
Session ID: G1300-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The micro-channel chip (micro total analysis system) attracts attention in the medical field. Generally, the photo lithography technology used in a semiconductor manufacture process is used as the manufacture method of a micro-channel chip die. However, there are many manufacturing processes like fabrication of a mask, the photo-resist application to a substrate, expensive facility of a clean room etc. So, this study examined how to form a fine groove by cutting with a micro endmill. This report examined experimentally the processing conditions which should be developed. As a result, we created the selection guideline of cutting conditions in which burr could be reduced.
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Katsuya KUGAI, Kazuma Shikii, Nobuhiro Nakamura, Satoshi Kubo
Article type: Article
Session ID: G1300-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Cress is one of the chief products in KUMANO. However, the kneading process of cress by hand requires very hard work, and this causes the low-efficiency of this product. So, we are going to develop the auto-kneading machine for cress so as to increase the productivity. In former report, we developed the proto-type of auto kneading machine, and carried out trial run. Even contact evaluation, we found this machine can provide kneaded cress like expert. So, this report will explain more detailed evaluation of the performance of auto-kneading machine. At first we set piquant level as the basis. But it mainly changes according to pre wet process more than kneading process. So we have to employ another basis. They are the volume of out coming juice during kneading process, the pull strength of kneaded leaf, and the micrograph of leaf with through ray. We found these three basis can describe the quality of kneading process.
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Yasuhiro TANI, Junji MURATA, Takeshi YANAGIHARA, MIyuki YAMADA
Article type: Article
Session ID: G1300-1-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Composite abrasives have been developed for improving the dispersibility and cleanability of the conventional glass polishing that uses cerium oxide abrasives. The composite abrasives are fabricated by adhering cerium oxide abrasives to the surface of polymer particles using a hybrid mixer. In this report, the effect of the shape and specific gravity of polymer particles on the polishing characteristics are investigated using aspherical poly-urethane particles and SiO2 mixed poly-urethane particles. The "golf ball-shaped" particles are found to be most effective for glass polishing. The removal rate increases with increasing the specific gravity of polymer particles.
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Makoto IIDA, Katuhiko SAKAI, Yasuo SUZUKI, Nobuaki IKEYA
Article type: Article
Session ID: G1300-1-5
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this work, the mechanical characteristics of CFRP molded by new hand lay-up method using epoxy resin is investigated. Three types of CFRP; autoclave molding method, conventional hand lay -up method, the new one, were prepared and compared in tensile test and bending test. The maximum stress of the new method CFRP in tensile test was 30% lower than autoclave one, but not less than conventional hand lay -up method. In bending test, the new CFRP shows 60% larger maximum tensile stress than conventional method and was comparable to autoclaved CFRP. The delamination of CFRP might have effect to maximum stresses.
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Tatsuya HIKICHI, Keiichi NAKAMOTO, Tohru ISHIDA, Yoshimi TAKEUCHI
Article type: Article
Session ID: G1300-1-6
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The use of 5-axis controlled machine tools that can take the arbitrary tool attitude is widely expanded with increasing complicated workpieces. In 5-axis control machining, the frequent variation in tool attitude makes the quality ofmachined surface worse. The influence of the variation in tool attitude is evaluated in the study, based on the experiment. An evaluation formula is proposed, considering the influence of both the tool attitude and the variation in tool attitude against the machined surface. Machining experiments are performed to confirm the validity. Moreover, the method that generates appropriate tool paths for finish machining is devised by utilizing the evaluation formula. This paper demonstrates the tool path to consider both the tool attitude to the machined surface and the variation in tool attitude.
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Tamao MURAMATSU, Tatsuya SUZUKI, Hideki TAKEZAWA, Naotake MHORI
Article type: Article
Session ID: S1304-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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To control the magnetic characteristic and shape machining of a permanent magnet, the neodymium magnet has been shaped with Electrical Discharge Machining that is the thermal energy machining. Enlarging input energy influences the decrease of the magnetic flux density on the machined surface. In this research, to observe decreasing appearance of it, shaped the permanent magnet surface with several difference machining conditions and remove the surface using small input energy condition. The following result was obtained that removing the surface has less influence of decrease the surface flux density on the part processed by a large input energy condition.
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Tatsuya SUZUKI, Hideki TAKEZAWA, Tamao MURAMATSU, Naotake MHORI
Article type: Article
Session ID: S1304-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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A permanent magnet is being used for various motor, medical devices and small speakers. Especially, neodymium magnet is the most powerful magnet in the Rare-earth metals. Therefore, there are many machining demand to Neodymium magnet. However permanent magnet is superior in mechanical properties, not suitable for non-contact machine tools. This research is focus on conductive of magnet, make a small hole in the magnet at EDM. The electrode is 1mm brass pipe and all machining performed from N pole. Machining time, Electrode wire length, surface magnetic flux density, Exit and entrance holes diameter differ by electrical conditions and machining method.
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Akihiro ITOH, Shinya HAYAKAWA, Fumihiro ITOIGAWA, Takashi NAKAMURA
Article type: Article
Session ID: S1304-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This paper observes the WEDMed surface of Carbon Fiber Reinforced Plastics (CFRP) in order to evaluate the influence of heat of electrical discharge on CFRP. WEDM of CFRP was carried out parallel to or perpendicular to fibers orientation, and obtained surfaces were observed using scanning electron microscope. It is found for the case of discharge current 45A that plastics around fibers is removed on the WEDMed surface by the heat of the electrical discharge, and carbon fibers are bare on the surface. On the other hand, for the case of discharge current 8A, plastics are remained around the fibers. These results indicate that the plastics removal can be avoided when small discharge current condition is selected. It is also found that the lack of the carbon fiber does not occur in wire EDM process whereas it occurs in cutting process.
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Soichiro Yamada, Shinya Hayakawa, Fumihiro Itoigawa, Takashi Nakamura, ...
Article type: Article
Session ID: S1304-1-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This paper investigates the coalescence of bubble and the ratio of pulse discharges generated in liquid, in bubble and around the bubble boundary in electrical discharge machining (EDM) process in order to discuss the effect of coalescence of bubble on material removal rate. The easiness of bubble coalescence was observed using a video camera. Then, continuous EDM process was carried out and pulse discharges were classified into above three categories by the rise time of discharge current. It is found that few pulse discharges are generated in bubble and the ratio of around the bubble boundary is large. It is also found that difficulty of bubble coalescence can prevent the scattered material from reattaching on workpiece surface.
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Takayuki TANI, Hiromitsu Gotoh, Naotake MOHRI, Yasushi Fukuzawa
Article type: Article
Session ID: S1304-2-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In recent micrcrEDM processes various kinds of thin tool manufacturing methods, including the wire electrical discharge grinding (WEDG) have been proposed to satisfy the growing need for very thin tools. This study describes the simultaneous machining of micropin and micro hole with composite power supply using zinc alloy tool electrode. The zinc alloy enters the state of complete wear according to an electrical condition. This condition was selected to the micropin forming, and the hole machining was executed according to the condition with comparatively low electrode wear.
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Akira OKADA, Takashi UMEJI, Yoshiyuki UNO
Article type: Article
Session ID: S1304-2-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In compression molding or injection molding of rubber products, small piece of rubber material sometimes remains on the metal mold surface after releasing the product because of strong adhesion of rubber to the surface. Therefore, cleaning of the metal mold surface is often needed, which makes the molding cycle time longer and the life time shorter. On the other hand, in EB polishing method developed recently, a large-area surface of metal mold can be instantly finished with small surface roughness less than 1μmRz. In addition, surface modification effect is greatly expected since thin resolidified layer is formed on the surface and the surface structure may change. In this study, the separation forces between molded rubber and metal mold surface are measured with tensile tester. The metal mold surfaces are treated by various surface coating and surface modification methods including EB polishing, in order to evaluate the releasability.
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Takaaki WATANABE, Shinya HAYAKAWA, Fumihiro ITOIGAWA, Takashi NAKAMURA ...
Article type: Article
Session ID: S1304-2-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This paper investigates the relationship between surface profile and laser absorptivity in laser welding of transparent thermoplastic resin parts in order to clarify the desirable profile which provides high laser absorptivity. A diode laser with 920 nm wavelength was used for laser irradiation and PMMA was used as a test piece. Sandblasting and hot pressing were used as the preprocessing method to form the roughness and the surface of the test pieces was observed using scanning electron microscope (SEM). Laser absorptivity of each test piece was also measured. It is found that surface on which squarish asperities 5 μm on a side, as well as small asperities less than 1 jam size, provides high laser absorptivity.
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Masafumi YAMAKAWA, Shinya HAYAKAWA, Takashi NAKAMURA, Tatsuya HASEGAWA
Article type: Article
Session ID: S1304-2-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this report the relation between principal stress direction around welded portion and welding strength in laser welding of thermoplastic plates is discussed by using photoelastic method. Principal stress difference and principal stress direction are measured by photoelasticiry and a change of photoelastic fringes for a load is observed. As a load for shearing strength test becomes large, the degree of fringes with principal stress difference at the edge of welded portion comes to be high particularly and the direction of a load have a great influence on lines of principal stress.
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Yoshinao MIYAHARA, Fumihiro ITOIGAWA, Takashi NAKAMURA
Article type: Article
Session ID: S1303-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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On Ti-alloy machining, it is problem that tool life is shortened by heat converging at cutting edge due to its low heat conductivity and production of saw-tooth chip. In this research, effect of oblique cutting is verified with comparing Ti-alloy with some materials and it is examined which material property is mainly associated with cutting temperature in oblique cutting. As a result of measuring chip temperature, it was found that the temperature rise with an inclination angle does not occur in Ti-alloy cutting although the total cutting energy increases with increasing in the inclination angle. Same tendencies were obtained in SUS430 and Brass cutting while, S45C cutting, large temperature rise took place. Consequently saw-tooth chip generation is strongly related to little temperature rise with the inclination angle.
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Koji TSUDA, Koichi OKUDA, Hiroo SHIZUKA, Masayuki NUNOBIKI
Article type: Article
Session ID: S1303-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This study deals with cutting properties of titanium materials in milling by an end mill with small diameter. Titanium is well-known as a difficult-to-cut material in conventional cutting. However, the cutting properties are not sufficiently made clear when the micro end mill less than diameter of 1 mm is used. In this study, mainly the tool wear and the surface roughness in micro end milling of pure Ti and Ti-6Al-4V have been experimentally investigated. As the results, it was found that the tool wear growth was not much when the cutting speed was changed to 200 m/min from 50 m/min. Furthermore, the surface roughness Rz of 0.3 μm and 0.6 μm were obtained in wet cutting at 200 m/min and 50 m/min respectively.
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Kohei HAMASAKI, Katsuhiko SAKAI, Yasuo SUZUKI
Article type: Article
Session ID: S1303-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The tool life in milling engine component becomes extremely short when the component has different materials such as iron and aluminum. In this study, suitable tools and machining conditions for simultaneous cutting was investigated. Cemented diamond, cemented carbide and cermet tools were tested. This experiment yields (1) Cemented diamond broke early. (2) Cemented carbide is chipped because of high feed rate per tooth.(3) Cermet may be adapted for simultaneous cutting and cermet can be decrease the manufacturing in cost.
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Takeshi SUZUKI, Mikihisa MURASE, Katsuyoshi OGAI, Shuji SUZUKI
Article type: Article
Session ID: S1303-1-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This paper presents the high performance and cost effective machining method for difficult-to-cut material such as Inconel 718. The machining of engine components for aerospacial vehicle often requires a special machine tool: broach machine because of the high accuracy and limited tolerance for machined parts. Wire discharge machining is quite useful tool for cutting difficult-to-cut material, though the speed of machining is relatively low and, the ordinary processing chamber is not enough large to settle the big component of jet engine. In this study, to raise the cutting speed, hybrid coolant nozzles were developed, and the NC index machine were integrated into the small WDM machine. Thus the high performance machining with small WDM machine and the high speed cutting of Inconel 718 were realized.
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Koki Ido, Takashi Inoue
Article type: Article
Session ID: S1303-1-5
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The nickel base high temperature alloys are generally considered difficult-to-cut due to its low heat conductivity and high tenacity. This paper deals with machinability grooving cutting of 64Fe-36Ni alloy. Specimens were end-milled to determine how cutting speed would affect tool wear and cutting force. The tool face tends to wear more significantly as the cutting speed increases. The faster cutting speed gives the cut surface smoother finish by burnishing effect.
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Hiroki KIYOTA, Fumihiro ITOIGAWA, Takashi NAKAMURA, Atsushi KAKIHARA
Article type: Article
Session ID: S1303-2-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In Inconel718 cutting with a cubic boron nitride (CBN) tool, notch wear caused by extruded built-up edge (BUE) along the cutting edge and secondary chip due to a side flow occurs significantly outside of the depth-of-cut line. The BUE extrusion behavior depends on tool geometry, such as chamfer angle, chamfer width and rake angle. The secondary chip easily forms if curled BUE is extruded unstably. On the other hand, the stable uncurled BUE extrusion causes neither the secondary chip formation nor the notch wear. In this study, the optimization of tool geometry for obtaining the stable BUE extrusion is attempted to suppress the notch wear.
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Takahumi TONSHO, Masao KOHZAKI
Article type: Article
Session ID: S1303-2-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this work, we attempt to develop the lubricious and hard films based on TiB_<2+α> for cutting of materials for aircrafts. In the experiment, we have prepared the TiB_2 and TiB_<2+α> thin films by DC magnetron sputtering using TiB_2 and TiB_2+10wt.%B target. We controlled the B content to improve the mechanical properties of the TiB_<2+α> films. The films having high hardness more than 30 GPa were able to be obtained under the low base pressure. And the TiB_<2+α> thin films showed the high critical load almost equal to that of TiN films. Moreover, at the optimized coating condition, the TiB_<2+α> films were produced on tungsten carbide cutting tools. And turning tests were carried out against Ti alloys by using the high speed precision lathe.
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Katsuhiko SAKAI, Katsunori SANO, Yasuo SUZUKI, Tokuo SHINMURA
Article type: Article
Session ID: S1303-2-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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This paper presents the high performance and cost effective grinding method for hardened steel by cBN wheel with segmented grooves. The surface finishing with high accuracy must be done by fine grain grinding wheel, though the such fine grain wheel may often cause the burn out during grinding, so the grinding rate is limited thus the grinding performance is relatively low compared with the coarse and medium grinding. In this research, evaluation of the improvement on grinding performance by making separated gaps on the grinding wheel. Grinding forces, temperatures of specimen and surface roughness of finished work pieces were studied and the mechanism of burn-out prevention was considered.
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Makoto SATO
Article type: Article
Session ID: S1303-2-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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An efficient power device is requested because of the CO_2 reduction. Because generation of heat is a little and the thermal conductivity is also high, the power device that composes on single-crystal SiC can be light miniaturized. However, because time hangs in making to the specular as for single-crystal SiC substrate, the cost of manufacturing is high. The high efficiency polishing that aimed at the high efficiency grinding in this report, invoked the oxidant to polishing single-crystal SiC, and used the ceria abrasive grain whose hardness is lower than single-crystal SiC was tried. High efficiency of 1300nm/h or more was obtained in both Si-face and result C-face, and surface-roughness Ra=0.2nm in Si-face was obtained. At this time, it turned out that there was no valence change of the Ce atom as a result of measuring XPS before and after polishing the ceria abrasive grain used.
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Hiromasa YAMAMOTO, Kentaro SATAKE, Hiroyuki SASAHARA, Toru NARITA, Mas ...
Article type: Article
Session ID: S1303-3-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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To achieve high speed rotary cutting of difficult-to-cut materials, this study investigates the effect of the tool peripheral speed on the thermal behavior and the tool failure. Rotary cutting and conventional single-point turning tests of stainless steel SUS 304 were carried out at the cutting speed of 500 m/min. Tool peripheral speeds were set in the range of 0 to 260m/min. The increase of the tool peripheral speed in rotary cutting reduced the amount of tool wear, while the severe tool wear was observed in single-point turning. However, the higher tool peripheral speed caused the higher tool surface temperatures, and the excessive tool peripheral speed increased the amount of tool rake wear. Testing results shows that there is the optimum tool peripheral speed which minimizes the amount of tool wears.
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Shigehiko SAKAMOTO, Yuma KAWAKAMI
Article type: Article
Session ID: S1303-3-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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CFRP (Carbon Fiber Reinforced Plastic) has higher specific strength, modulus of elasticity and so on. CFRP is remarkably applied for structural parts in the aviation and automobile industries and so on. Drill-out of CFRP which is one of the most important cutting techniques is currently carried out in the many industrial factories. In this research, we tried to make high accuracy drill holes by helical milling on the CFRP plates. By using the helical method with each cemented-carbide end mill cutter, high quality holes on the CFRP plates are obtained without burrs, chippings, and so on. Up-cut helical milling method is suitable for drill of laminated material because of tool trajectory on the helical motion.
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Shota YOKOI, Kastuhiko SAKAI, Yasuo SUZUKI, Nobuaki IKEYA
Article type: Article
Session ID: S1303-3-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this research, varying hole shape and surface are investigated under following conditions^ various cutting speed, feeding speed, and types of drill. Experiments were performed in four different cutting speeds:20,60,100,and 140[m/min].A non-diamond coated carbide drill and a diamond coated carbide drill were used in experiment for the comparison. In the result, the relatively best shaped hole with less burrs was drilled at the feeding speed 20[m/min].The hole drilled by diamond coated drill was better than that of non-diamond coated drill: less burrs and better shape of the hole. Moreover, diamond coated drill had less wear during drilling process than non-diamond coated drill. Also, strongly warped angle diamond coated drill drills the hole with better shape and less burrs than that of weakly warped angle diamond coated drill; however, the blade of strongly warped angle drill is easy to be chipped since the blade is sharp.
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Hiro OHZEKI, Hikaru HOSHI, Eiichi HARA, Yoshio HASUMI, Fumihito ARAI
Article type: Article
Session ID: S1303-3-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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A machining system that can be operated at a predetermined cutting force by changing the feed rate based on cutting force signals measured by a piezoelectric type of dynamometer has been developed. This technique provides a basis for CFRP (Carbon Fiber Reinforced Plastic) drilling under a stable cutting state during the process. As a result of drilling tests with DLC (Diamond-like Carbide) coated carbide drills, the newly developed system can machine through-holes without significant delamination on CFRP laminates. It is confirmed that this system can optimize drilling process by controlling the feed rate based on the cutting force signals through the tests.
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Yoichiro JIDO, Fumiaki TAKAGI
Article type: Article
Session ID: S1302-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In order to protect global environment, various eco-friendly machining methods have been reported. In this paper, the extension of tool life in water soluble cutting fluid was studied by optimization of the fluid formulation as the most effective way to improve circumstances for cutting difficult-to-machine materials such as titanium alloy. As continuous fluid supply to cutting edge is important, the injection of fluid to the metal under high temperature was examined and the test fluid was formulated by using the fluid material which showed good injection. Test fluid we developed successfully extended tool life in both milling titanium alloy and drilling heat resistant super alloy.
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Kenji YAMAGUCHI, Masahiro MORITA, Yasuo KONDO, Satoshi SAKAMOTO
Article type: Article
Session ID: S1302-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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To reduce the management cost and environmental load of water-soluble coolant, it is effective to extend the live time of coolant. In order to extend the lifetime of water-soluble cutting coolant, user must observe and maintain the quality of coolant. Especially, the concentration of water-soluble coolant fluctuates greatly. However, the conventional water-soluble coolant concentration monitoring method is unfit for automatic measurement. In this study, we propose a newly developed concentration sensor for water-soluble coolant. The sensor measures the concentration of the water-soluble coolant in the storage tank at all times. In this report, we examined the basic performance and problems of the developed sensor.
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Satoshi OKUBO, Yuichi MIURA, Tomoyuki KASUGA, Hiroshi MORITA, Takayuki ...
Article type: Article
Session ID: S1302-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In grinding, airflow generated around the surface of the grinding wheel rotating at high speed, suppresses the grinding fluid (coolant) from reaching the grinding point. To break this airflow, a large amount of coolant has been supplied. In this study, technology has been developed so that coolant will reach the grinding point even with small flow rate, whereby airflow around the grinding wheel surface is intercepted above the grinding point. Grinding test has confirmed that in high wheel speed area, grinding performance equivalent to that of the conventional method can be achieved with half the coolant supply, using the developed technology.
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Kenji TAKAHARA, Toshiaki WAKABAYASHI, Norio SEMBONGI, Junichi SHTBATA, ...
Article type: Article
Session ID: S1302-1-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Near-dry machining attracts increasing attentions for environmental and economical benefits and MQL machining has been recognized as the most representative near-dry method. Recent concern for environmentally friendly manufacturing further encourages the attempts at applying near-dry operations to machining of difficult-to-cut materials. Since stainless steels have been considered to be a sort of difficult-to-cut material, this paper investigated the cutting performance of various near-dry methods, that is regular MQL and hybrid mist operations, in end milling of four different stainless steels from the view point of the longer tool life. As a result, it was found that the near-dry machining demonstrated the effectiveness in elongating the tool life and this effectiveness depended on the types of the stainless steels.
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Norio SEMBONGI, Junichi SHTBATA, Satoshi SUDA, Wataru OBAYASHI, Kenji ...
Article type: Article
Session ID: S1302-1-5
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In machining of aluminum and its alloys, since they have highly adhesive characteristics, effective lubrication is often necessary to prevent their accumulative transfer on the tool and the resultant chip jamming. This study therefore proposes novel cutting fluids based on such chemical compounds including oxygen as ester, alcohol and acid. In particular, some specific alcohols have demonstrated the exceedingly high performance in tapping of aluminum compared with ordinary successful cutting fluids comprising extremely pressure additives. The study has further examined the performance of those oxygen-including compounds as a MQL fluid in near-dry machining.
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Yasuhiro KAMATA, Toshiyuki OBIKAWA
Article type: Article
Session ID: S1302-1-6
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Inconel 718 is one of a family of nickel-base superalloy. However, Inconel 718 has disadvantageous properties for machining. These properties shorten tool lives. Therefore, it is difficult to increase the cutting speed of Inconel 718. But high-speed and high-efficiency machining is demanded. In this study, the high speed finish-turning of Inconel 718 was conducted. To improve the tool life, the authors proposed the new lubrication method called "Air Jet Assisted (AJA) Machining," in which the compressed air was applied to the normal wet cutting. It was found that this method improved the tool life in comparison with conventional wet cutting.
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Keiichi KAWATA, Fumihiro ITOIGAWA, Takashi NORIHISA, Kazumasa ISHIKAWA
Article type: Article
Session ID: S1302-2-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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It is expected that driven rotary tool with multi-tasking lathe provides high-speed machining and long tool life for super-heat-resistant alloy. In this paper, lubrication effect of driven rotary tool with textured surface was investigated. Experimental results show that coefficient of friction under the clockwise tool rotation is smaller than that under the counterclockwise tool rotation. Additionally, textured surface on rotary tool can carry fluid into the chip-tool interface to provide better lubrication.
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Naohiro NISHIKAWA, Yoshinori SATO, Toshirou IYAMA, Masahiro MIZUNO, No ...
Article type: Article
Session ID: S1302-2-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In tills investigation, water recycling and reuse is evaluated for the electric rust preventive machining method which uses only water with machining. Water reuse is unable to be conducted by conventional chip sedimentation and separation method, because ferrous chip is corroded by water and it contaminates workpiece and machine. So, new rust prevention method for chip sedimentation is proposed and developed. The electric rust preventive chip sedimentation tank is that cathode plate is laid on acrylic tank and anode is installed in inside tank wall. In addition, when chip sedimentation is conducted, electric rust prevention is carried out with slight current supplying by DC power supply. And rust prevention effect is confirmed experimentally.
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Naohiro NISHIKAWA, Yoshinori SATO, Toshirou IYAMA, Masahiro MIZUNO, No ...
Article type: Article
Session ID: S1302-2-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Because in the conventional machining fluid such as cutting oil and grinding fluid contained several chemicals, enormous disposal cost and environmental load is occurred. Therefore in this investigation, electric rust preventive machining method which uses only water for machining fluid is developed. Because using only water without extreme pressure agents, oil and so on, this method saves much work in a disposal of used machining fluid. In this paper, supporting electrode (anode) is developed to prevent effectively rust generation of workpiece and electro-magnetic chuck and the optimized rust prevention current was verified. As a result, rust prevention of workpiece and electro-magnetic chuck when use supporting electrode of noncontact type is achieved by very low current of 0.1A (6.8V: 0.68W, one workpiece, 1 hour), 0.2A (10V: 2W, two workpieces, 1 hour). Moreover, the supporting electrode of two types is developed, and the characteristics were compared.
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Yasuhiro Inamasu, Makoto Fujishima, Morihiro Hideta
Article type: Article
Session ID: S1302-2-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Energy-saving technology has lately attracted considerable attention as a means to reduce carbon dioxide emissions. In order to reduce these emissions, in the machine tool field it is most important to reduce power consumption. This paper investigates the reduction of energy consumption by suitable cutting condition. Power consumption can be reduced by higher cutting feed rate. Power consumption can be reduced by increasing the values of cutting condition, which shortens cycle time.
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Toshiyuki Okita, Yoshihiko Yamada, Yoshimasa Kuwano
Article type: Article
Session ID: S1302-2-5
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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Recently in die and mold machining, there are demands for further reduction of lead time and cost to increase global competitiveness, and 5-axis machining is drawing its attention as a solution. With 5-axis machining, tilting of tool allows highly rigid thick tooling to be used over wide area, which enables reduction both machining time and number of tool used. But unlike conventional 3-axis machining, complex thinking process such as selecting the posture of tool taking in account of collision is needed, which distresses the operator and also consumes great portion of time compared to actual machining time. Here, to shorten the total lead time starting from process planning to machining, support system which automates process planning, which allows even novice to plan high efficiency indexed 5-axis process in short time, has been developed.
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Akiyoshi Kobayashi, Daichi Mori
Article type: Article
Session ID: S1302-2-6
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The most suitable eco-machining is the perfect dry cutting (zero emission cutting). In order to achieve the zero emission end milling for the difficult-to-cut material like a stainless steel, we have developed a new type nitride hard film coated end mill, before. Althogh the end mill performed the excellence cutting characteristics (long tool life), the mechanism is still not clarified. Therefore, the fundamental and tribological characteristics of 3kinds of nitride film are examined by the orthogonal interrupted cutting method that a rotary work is interrupted cut by plate type coated specimen (corresponds to end mill).
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Yasutaka TSUJI, Masahiro KURODA, Yoshitaka IMOTO, Eiji KONDO
Article type: Article
Session ID: S1401-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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The railway rolling stock planning is a basic scheduling in railway transport, which assigns physical train units to given time table services and determines a roster of the train units. This planning also involves a scheduling of periodical inspection for the train units. We have proposed an Ant Colony Optimization (ACO) based approach to solve this planning problem. In this paper, local search methods are developed to enhance the proposed ACO's performance for tackling a large-scale problem. Then, multiple ACO with several colonies is also proposed to treat a multi-objective problem. The effectiveness of the enhanced ACO approach is demonstrated through numerical experiments.
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Yoshihiro KOJIMA, Yusaku YAMAMOTO, Shinji IMAHORI, Shao-Liang ZHANG
Article type: Article
Session ID: S1401-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this paper, we propose a heuristic algorithm based on the Branch-and-Bound Method for solving a Stock Management Probrem. In this algorithm, we divide the problem into small ones and solve them repeatedly. This algorithm achieves considerable speedup over the exact Branch-and-Bound Method. However, we need more speedup to use this in practical situations. To this end, we improve the pruning strategy in the Branch-and-Bound Method. In particular, we define a relaxation problem that can easily be solved by Dynamic Programming and use its solution for pruning. As the result of this, we can get efficient approximate solution in practical time using standard PC.
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Yoshiyuki KARUNO, Hiroshi NAGAMOCHI, Akira NAKASHIMA, Kougaku YAMASHIT ...
Article type: Article
Session ID: S1401-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this paper, we consider a combinatorial optimization problem of scheduling n jobs of block type on linearly aligned m identical machines. Each job J_j is characterized by four integers, an arrival time a_j, a processing time p_j, the number q_j of consecutive machines required, and a weight w_j. There is a choice for eachjob whether the aligned machines serve it or not. If the aligned machines choose a job J_j, they gain the weight w_j as their profit. However, they have to start the service of the chosen job promptly after it arrives, selecting q_j consecutive machines in the alignment. The objective is to find a feasible schedule that maximizes the weighted number of chosen jobs. It has already been known that the scheduling problem is NP-hard for an arbitrary m. In this paper, we propose a polynomial time heuristic algorithm based on a transformation into the minimum cost flow problem, and prove that the approximation ratio is ⌞w/q_<min>⌟/⌞m/q_<max>⌟, where q_<min>=min_<1≤j$le;>{q_j} and q_<max>=max_<1≤j$le;>{q_j}.
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Yoshihiro Murakami, Hironobu Uchiyama, Junichi Kurata
Article type: Article
Session ID: S1401-1-4
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In a computerized scale, several products having different weights are packaged together so that the sum weight should be closest to a given target weight. The problem is how to overcome trade-off conflict occurring in solving combinatorial optimization with constraint satisfied. Therefore, we propose a new objective function, that is different from the original one, and both of them are combined with a tuning parameter. By varying this tuning parameter, such an optimal solution is obtained that suits user's needs in the meaning of Pareto optimum.
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Shinji IMAHORI, Yoshiyuki KARUNO, Yui YOSHIMOTO
Article type: Article
Session ID: S1401-1-5
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this paper, we deal with a duplex packing operation such that an automatic combination weigher chooses two disjoint subsets l' and l" from the set l of the current n items to produce two packages of foods. The primary objective of lexicographic bi-criteria duplex food packing problem is to minimize the total weight of chosen items for two packages, making the total weight of each package no less than a specified target weight T. The second objective is to maximize the total priority of chosen items for two packages. The priority of an item is given as its duration in hopper. We prove that the lexicographic bi-criteria duplex food packing problem can be solved in O(nT^2) time by dynamic programming if all input data are integral.
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Tomoya OSADA, Rei HINO
Article type: Article
Session ID: S1402-1-1
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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A new re-scheduling procedure is proposed to accept an uncertain irregular job without the reduction of the product volume in the cyclic mass manufacturing. The proposed procedure is focused on idle times existing on every machine except bottleneck machine, and the times are utilized to operate the irregular job. In the present paper, the fundamental concept of the procedure is explained and an example of re-scheduling result is shown.
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Tatsuhiko SAKAGUCHI, Atsushi TSUJI, Keiichi SHIRASE
Article type: Article
Session ID: S1402-1-2
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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It is important to manage the manufacturing system efficiently to acquire competitive edge in the current era of advanced information technologies and market globalization. Production scheduling is one of the important elements for managing the manufacturing system. Mass customization with small quantity production is a main trend these days, so information divergence tends to increase between the detailed daily work schedules in manufacturing level and mid/long-term schedule in management level. In this research, the cooperated scheduling method in which the mid/long-term scheduler and the daily work scheduler fine-tune independently each schedule is proposed.
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Tatsuhiko SAKAGUCHI, Masaki UCHIDA, Keiichi SHIRASE
Article type: Article
Session ID: S1402-1-3
Published: September 04, 2010
Released on J-STAGE: August 01, 2017
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In this research, to deal with the problem of causing the difference between the scheduling result with the scheduler and the progress report of the manufacturing process of the manufacturing premise even if the very best schedule is prepared beforehand, and leading to the failure of the plan, making the manufacturing execution system to collect, to arrange, to analyze results information on the manufacturing premise, and to feed back to production management and the scheduling system.
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